Selecting the right electrical balance of systems (EBOS) for your solar project—whether IPCs or Shoals BLA—can be challenging. At Shoals, we frequently receive questions about this choice, as reliable, high-quality electrical solutions are essential for long-term success. In this blog, we compare the installation processes of Shoals’ Big Lead Assembly (BLA) and Insulation Piercing Connectors (IPCs), showing why BLA is the safer and more dependable option. Based on insights from our eBook The Safer Choice: Shoals BLA vs. IPCs, we highlight how Shoals’ pre-assembled, factory-tested BLA offers a simpler, more reliable installation compared to IPC’s complex, error-prone process.
Unrealistic cleanliness expectations
IPC installation videos often emphasize the need for a spotless environment, showcasing lab-like conditions where the installer’s gloves and wires are perfectly clean. However, in real-world conditions, it’s nearly impossible to avoid dust, dirt, moisture, and other elements. This makes the demand for such cleanliness impractical. Shoals BLA, on the other hand, can be installed in less-than-perfect environments without concern. Our factory-made and rigorously tested EBOS solutions are designed to be environment resistant, thanks to their patented protective undermold/overmold structure.
Wire centering is not easy
IPC installation requires precise cable alignment, a step repeated frequently in the instructions. Even slight misalignments or bends can compromise the connection quality. Shoals’ BLA eliminates this issue with a pre-assembled design that ensures reliable performance without the need for perfect alignment in the field.
Using the right tools
IPC manufacturers specify the exact tools and settings for proper installation. With tools like wrenches, if the wrong setting is chosen, the bolt may be too tight or too loose, compromising the connection quality. Unfortunately, there’s no way to visually confirm whether the installation is correct, as IPCs act like a “black box,” concealing potential issues. Over-tightening the bolt can shear it off prematurely, causing poor contact, increasing resistance, and generating heat that may lead to hotspots or thermal issues. Proper torque and speed are essential for a secure connection, but even minor errors—like adjusting the secondary hex nut—can cause damage. Shoals BLA eliminates this risk with a foolproof design, ensuring no accidental damage during installation.
The gel challenge
Some IPC manufacturers use gel to prevent aluminum oxide from forming at the aluminum-copper interface. It’s important to keep the gel clean, because if contaminated it can impact the longevity of the solar project. However, the gel is sticky and easily attracts contaminants like dirt, oils, and debris. Keeping it clean is critical for maintaining the connector’s insulating properties, but avoiding contact with the gel during installation is nearly impossible. Installers are instructed to carefully handle wires and plastic covers to avoid disrupting the gel, but the process—bending wires, securing covers, and aligning them—often makes contamination inevitable. With Shoals BLA, there’s no need to worry about gel. Our solution is pre-assembled and designed to withstand environmental factors without the need for such meticulous handling.
No second chances
Once IPCs are installed, there is no straightforward way to verify whether the installation meets the necessary standards, as there is no UL standard for guidance. This raises concerns: Was the right tool used? Was the IPC compressed properly? Installers can’t really conduct hipot tests in the field. After the installer crimps the wire, the connection is permanent, and inspecting the crimp requires discarding the housing and using a new one. If the crimp fails and leaves an open cavity, oxygen can enter, potentially leading to failures. In this scenario, the warranty responsibility falls entirely on the installer. In contrast, Shoals handles everything in a controlled factory environment, ensuring both reliability and compliance.
Final testing is impossible
Another critical issue with IPC installations is the lack of a final testing procedure. Once the compression lug is connected to the wire, there’s no easy way to check if it was done correctly. How can we ensure the copper isn’t overly compressed during installation? Is it even possible to inspect these connections properly in the field? Conducting pull tests or running high-voltage measurements across the project is not practical. As a result, there’s no reliable way to confirm that the connections are neither too loose nor too tight, which could damage wire strands. Prefabricated solutions, however, are rigorously tested before they leave the factory. Shoals provides plug-and-play solutions that are so user-friendly they can be installed by anyone. Our patented hermetically sealed overmold/ undermold design ensures that all components arrive onsite with these steps already completed and tested. This rigorous testing process is how Shoals delivers additional assurance and reliability.
Repair kits for IPCs
IPC manufacturers offer repair kits for fixing installation mistakes, acknowledging that errors are quite likely. However, these kits only address visible issues. Subtle mistakes, such as improper placement or incorrect harness length, might go unnoticed and unresolved.
How do I help ensure my project’s safety and longevity?
Whether you work for a project developer, a project owner, or an EPC, choosing the right EBOS solutions for your solar project is a critical decision that should take place early in the process. At Shoals, we have the right solar power experience and expertise and industry leading EBOS and wiring solutions to help ensure your project is safe, durable and lasts long. Our EBOS solutions offer it all: durability of materials, innovative design, and strong performance under various environmental conditions. We provide detailed product specifications and test results to back up our claims. We also offer initial design and engineering support to optimize your installations, as well as long-term after-sales care for ongoing maintenance and troubleshooting. To learn more about how you can pick EBOS solutions that are right for your solar project and help ensure its safety and reliability, read our eBook, The Safer Choice: Shoals BLA vs. IPCs. Contact us today to discover how our patented flagship trunk bus solution – Shoals BLA – is key to long-lasting solar installations.
The Safer Choice: BLA vs. IPCs for Solar
Download our eBook to choose EBOS solutions that guarantee safety, reliability, and longevity of your solar installations.
